US20160214273A1 - Method and apparatus for casting concrete products - Google Patents
Method and apparatus for casting concrete products Download PDFInfo
- Publication number
- US20160214273A1 US20160214273A1 US15/007,279 US201615007279A US2016214273A1 US 20160214273 A1 US20160214273 A1 US 20160214273A1 US 201615007279 A US201615007279 A US 201615007279A US 2016214273 A1 US2016214273 A1 US 2016214273A1
- Authority
- US
- United States
- Prior art keywords
- section
- casting
- restricted cross
- sections
- trowelling
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000005266 casting Methods 0.000 title claims abstract description 79
- 238000000034 method Methods 0.000 title claims abstract description 12
- 238000005056 compaction Methods 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 3
- 230000000712 assembly Effects 0.000 description 2
- 238000000429 assembly Methods 0.000 description 2
- 238000009749 continuous casting Methods 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 238000010008 shearing Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
- B28B1/093—Producing shaped prefabricated articles from the material by vibrating or jolting by means directly acting on the material, e.g. by cores wholly or partly immersed in the material or elements acting on the upper surface of the material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
- B28B1/261—Moulds therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
- B28B3/22—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded by screw or worm
- B28B3/228—Slipform casting extruder, e.g. self-propelled extruder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
- B28B3/22—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded by screw or worm
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
- B28B1/084—Producing shaped prefabricated articles from the material by vibrating or jolting the vibrating moulds or cores being moved horizontally for making strands of moulded articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
- B28B1/265—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor pressure being applied on the slip in the filled mould or on the moulded article in the mould, e.g. pneumatically, by compressing slip in a closed mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/29—Producing shaped prefabricated articles from the material by profiling or strickling the material in open moulds or on moulding surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
- B28B3/26—Extrusion dies
Abstract
Description
- This application claims benefit of Finnish Patent Application No. 20155054, filed 27 Jan. 2015, the entire contents of which are incorporated herein by reference for all purposes.
- 1. Field
- The present disclosure relates to casting of prefabricated concrete products with a substantially horizontal slipform casting, where concrete mass is fed through a restricted cross-section, which restricted cross-section proceeds along with the casting.
- 2. Description of Related Art
- Prefabricated concrete elements and products, such as hollow-core slabs and solid concrete slabs, are conventionally cast as slipform casting on elongate casting beds in a continuous casting process. The length of said continuous casting process is defined either on the basis of the combined length of the elements to be cast, or on the basis of the maximum length of the casting bed. The length of casting beds used in slipform casting can be up to 150-200 m, depending on the size of the element factory. After the slipform casting equipment has cast a continuous slab on the casting bed, the cast concrete mix is allowed to cure on the casting bed. When the concrete mix is cured, the uniform cast concrete slab is sawed in predetermined lengths on the basis of the targets of usage of the final elements, and the sawn concrete elements are lifted off the casting bed to storage, to wait for transportation to their respective locations of usage.
- In slipform casting devices, concrete mix is fed either in one or several stages to a casting mold moving along with the casting device, said mold being formed by side walls of the mold and vibrating beam defining the top surface of the mold, together with the casting bed. The side walls and vibrating beam of the casting mold perform a vibrating and/or trowelling compacting motion for compacting the concrete product. When casting hollow-core slabs, the slipform casting device is provided with means for forming the cavities. Generally a slipform casting device is a casting machine moving on a stationary casting bed along with the casting process, but a slipform casting device can also be realized as a stationary casting station, in which case the casting bed moves along with the casting process with respect to the casting station.
- One of the most common types of slipform casting devices is an extruder. In an extruder-type slipform casting device, the concrete mix is fed on feed screws that extrude the concrete mix under pressure to the slipform casting mold. Thus, in an extruder-type casting device, the feeding of the concrete mix to a slipform casting mold is carried out in one single feed step. When casting hollow-core slabs, at the end of the feed screws is attached hollow-core forming members, such as hollow-core mandrels.
- The form of the slipform cast product is defined by the restricted cross-section, i.e. the slipform casting mold, formed in an extruder by the top surface of the casting bed, and side plates and top trowelling plate. Thus the top trowelling plate of the slipform casting mold defines the shape of the upper surface of the product to be cast.
- In the present day buildings and constructions the requirements for concrete elements vary greatly, which include their shapes also. Due to the compaction effect of the slipform mold in slipform casting, the change of the shape of the cross-section of the product to be cast from the normal rectangular is problematic.
- The present disclosure provides a solution for casting concrete products with wider variety of cross-sectional shapes with an extruder-type slipform casting process. This is achieved with a novel trowelling plate which is divided in plurality of level sections in relation to the casting direction, where the sections are moved in trowelling motion at different phases or at different speeds than the adjacent sections.
- Preferably the adjacent sections are moved in back-and-forth trowelling motion in opposite phases at same speed so, that the adjacent sections move opposite direction through the whole movement distance. This achieves the greatest shearing compaction effect to the upper surface of the product to be cast.
- With the sectional trowelling plate of an embodiment of the invention, the effect of the shearing compaction in the concrete product to be cast is enhanced, especially in the corners and angles of the product, which allows wider variety for the upper surface forms. This is not possible with prior art single part trowelling plates, since these cannot achieve sufficient compaction for corners and angles within the area of the trowelling plate.
- In the method of an embodiment of the invention for casting prefabricated concrete products with a substantially horizontal slipform casting process, where concrete mass is fed under pressure through a restricted cross-section defining the product to be cast, the upper surface of the restricted cross-section is formed of a plurality of sections, and the sections are moved in back and forth trowelling motion in the casting direction, wherein the adjacent sections are moved at different phases and/or at different speeds. The different movement phases of speeds of the adjacent sections improve the compaction of the upper surface of the product to be cast and provide sufficient compaction for corners formed on the upper surface of the product to be cast.
- The present disclosure also provides an apparatus for casting prefabricated concrete products with a substantially horizontal slipform casting, which apparatus comprises a restricted cross-section defining the product to be cast. The restricted cross-section is formed with side plates of the apparatus defining the side surfaces of the restricted cross-section, an upper surface of the casting bed defining the bottom surface of the restricted cross-section, and with a top trowelling or vibrating beam or plate defining the upper surface of the restricted cross-section. The apparatus also comprises elements for feeding concrete mass to the restricted cross-section, such as feed screws and/or concrete mass containers for example, in at least one feed stage. In the apparatus of an embodiment of the invention, the upper surface of the restricted cross-section comprises a plurality of sections, and the apparatus comprises devices for moving adjacent sections back and forth in trowelling motion at different phases and/or at different speeds.
- In an embodiment of the invention at least some of the adjacent sections of the upper surface of the restricted cross-section are arranged at an angle relative to each other. This embodiment allows for casting of different upper surface shapes for the products to be cast.
- In an embodiment of the invention between the adjacent sections of the upper surface of the restricted cross-section is arranged a gap of 0.5-2 mm. This distance is sufficient so that the movement of adjacent sections does not hinder each other but still small enough so that the concrete mass under pressure within the restricted cross-section does not excessively rise through the gap.
- In an embodiment of the invention the upper surface of the restricted cross-section consist of sections in vertical orientation and horizontal orientation in relation to the lower surface of the restricted cross-section. This embodiment allows casting of concrete products with vertical extensions on the upper surface of the product to be cast, such as T and TT slabs.
- In an alternative embodiment of the invention between the adjacent sections of the upper surface of the restricted cross-section is arranged a gap of 10-20 mm. This embodiment allows reinforcement bars and other similar parts extending from the upper surface of the concrete product to be cast pass through the trowelling plate, and through the whole casting machine, via the said gaps.
- The features defining a method of the invention are more precisely presented as a method for casting concrete products with a substantially horizontal slipform casting process, where concrete mass is fed under pressure through a restricted cross-section defining the product to be cast, characterized in that the upper surface of the restricted cross-section is formed of a plurality of sections adjacent in the casting direction, which sections are moved in back and forth trowelling motion in the casting direction, wherein the adjacent sections are moved at different phases and/or at different speeds, and the features defining an apparatus of the invention are more precisely presented as an apparatus for casting concrete products with a substantially horizontal slipform casting, which apparatus comprises a restricted cross-section defining the product to be cast, and elements for feeding concrete mass under pressure to the restricted cross-section, characterized in that the upper surface of the restricted cross-section comprises a plurality of sections adjacent in the casting direction, and the apparatus comprises devices for moving adjacent sections back and forth in trowelling motion at different phases and/or at different speeds.
- In the following an embodiment of the invention is discussed in greater detail in the sense of example and with reference to accompanying drawings, where
-
FIG. 1 shows schematically an extruder-type slipform casting apparatus, -
FIG. 2A shows an embodiment of a trowelling plate assembly of an embodiment of the invention, -
FIG. 2B shows an alternative embodiment of a trowelling plate assembly of the invention, -
FIGS. 3A and 3B shows examples of concrete product shapes cast with a trowelling plate of an embodiment of the invention. -
FIG. 1 shows schematically an extruder-typeslipform casting apparatus 1, which is operated during slipform casting process by feeding concrete mass from aconcrete mass container 2 to feedscrews 3, which feed screws extrude the concrete mass under pressure in a slipform casting mold formed by acasting bed 5,side plates 6, and atop trowelling plate 7. After thetop trowelling plate 7 is located alevelling plate 8. At the downstream end of thefeed screws 3 is connected core forming members ormandrels 4, which also restricts the slipfom casting mold and form cores as longitudinal voids in the slab to be cast. The concrete mass is compacted during the slipform casting process by the rotating motion of thefeed screws 3 extruding the concrete mass achieved with a drive motor 9, and by back-and-forth movement in the casting direction of the feed screws and thecore forming members 4 achieved with adrive motor 10. The outer surfaces of the product to be cast are compacted by back-and-forth movement of theside plates 6, and trowelling motion of the top trowelling plate achieved with adrive motor 11. -
FIGS. 2A and 2B shows embodiments of trowelling beam assemblies 12, 12′ of the invention, which form the top surface of the restricted cross-section of a slipform mold forming the product to be cast. - In the embodiment of
FIG. 2A thetrowelling beam assembly 12 comprises aframe part 13, through which the trowelling beam assembly is connected to the frame of the extruder-type slipform casting machine, amotor 11 for moving the threetrowelling plate sections motor 11 rotates a crankshaft (within the assemblies inFIGS. 2A and 2 b) extending horizontally in transversal direction in relation to the movement directions of the trowelling plate over the trowellingplate sections plate sections plate sections frame part 13 viaswivel arms 14. - After the
trowelling plate sections plate 8, which finishes and levels the upper surface of the concrete product to be cast. - In the embodiment of
FIG. 2A the trowelling plate comprises threesections sections sections - The embodiment of
FIG. 2B corresponds to the embodiment ofFIG. 2A with the exception of the shape of thetrowelling plate sections 7 a′, 7 b′ and 7 c′, and the shape of the levellingplate 8′. - In the embodiment of
FIG. 2B thesections 7 a′ and 7 c′ at the sides of the trowelling plate are formed so, that they comprise both vertically and horizontally extending trowelling surfaces, and themiddle section 7 b′ comprises only horizontally extending trowelling surface. The shape formed for the upper surface of the product to be cast can best be seen from the shape of the levellingplate 8′, and an example of the shape of a concrete product cast with this trowelling plate is shown inFIG. 3B . -
FIGS. 3A and 3B shows examples of concrete product shapes cast with a trowelling plate of an embodiment of the invention. As mentioned in previous paragraph, the trowelling plate assembly ofFIG. 2B is used in casting the concrete product shape ofFIG. 3B . - The casting of concrete product shape show in
FIG. 3A requires trowelling plate formed of 5 to 9 sections. The side sections of the trowelling plate may be formed as substantially L-shaped trowelling both horizontal and vertical surfaces of the concrete product with a single section, and the middle portion may be formed with a substantially U-shaped trowelling plate section. Alternatively, each of the horizontal surfaces and vertical surfaces connecting the horizontal surfaces may be trowelled with a separate troweling plate sections. - The specific exemplifying embodiments of the invention shown in figures and discussed above should not be construed as limiting. A person skilled in the art can amend and modify the embodiments in many evident ways within the scope of the attached claims. Thus the invention is not limited merely to the embodiments described above.
Claims (10)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FI20155054 | 2015-01-27 | ||
FI20155054A FI126200B (en) | 2015-01-27 | 2015-01-27 | Method and equipment for casting concrete products |
Publications (2)
Publication Number | Publication Date |
---|---|
US20160214273A1 true US20160214273A1 (en) | 2016-07-28 |
US10434681B2 US10434681B2 (en) | 2019-10-08 |
Family
ID=55069746
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US15/007,279 Expired - Fee Related US10434681B2 (en) | 2015-01-27 | 2016-01-27 | Method and apparatus for casting concrete products |
Country Status (7)
Country | Link |
---|---|
US (1) | US10434681B2 (en) |
EP (1) | EP3056328B1 (en) |
CN (1) | CN105818251B (en) |
ES (1) | ES2671029T3 (en) |
FI (1) | FI126200B (en) |
NO (1) | NO3056328T3 (en) |
RU (1) | RU2645025C2 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN107756600A (en) * | 2017-11-20 | 2018-03-06 | 上海师范大学 | Cement section of jurisdiction arc surface receives water floating device automatically |
US20180133923A1 (en) * | 2016-11-14 | 2018-05-17 | Elematic Oyj | Method and apparatus for casting prefabricated concrete products |
US20200254647A1 (en) * | 2019-02-12 | 2020-08-13 | Elematic Oyj | Method for manufacturing prefabricated concrete products |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN112454615A (en) * | 2020-11-27 | 2021-03-09 | 冯万芬 | Precast concrete spare apparatus for producing |
Family Cites Families (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB879396A (en) * | 1958-06-06 | 1961-10-11 | Bohumir Kula | A device for the manufacture of building blocks or panels |
US4046848A (en) | 1970-06-11 | 1977-09-06 | Dyform Concrete (Prestressed) Ltd. | Extrusion machine for making articles of cement-like material |
SU541914A1 (en) * | 1974-06-04 | 1977-01-05 | Азербайджанский Научно-Исследовательский Институт Гидротехники И Мелиорации | Device for laying concrete mixes |
SU636091A1 (en) | 1977-02-07 | 1978-12-10 | Ярославский политехнический институт | Concrete mix compacting device |
FI74649C (en) | 1984-11-08 | 1988-03-10 | Partek Ab | Method and apparatus for casting concrete products. |
US5123831A (en) * | 1991-05-16 | 1992-06-23 | Esa Enqvist | Concrete extrusion machine |
FI110174B (en) * | 1994-04-07 | 2002-12-13 | Valkeakoski Extec Oy Ltd | A device for producing a concrete product |
CN2212491Y (en) | 1994-09-05 | 1995-11-15 | 周炳辉 | Multi-purpose wall partition shaper |
US6331069B1 (en) | 1998-01-14 | 2001-12-18 | George Putti | Concrete extrusion machine and spiral conveyor therefor |
FI117130B (en) | 2001-06-27 | 2006-06-30 | Consolis Technology Oy Ab | Method and apparatus for making concrete product |
FI20020193A0 (en) | 2002-02-01 | 2002-02-01 | Addtek Res & Dev Oy Ab | Method and apparatus for casting concrete product |
US7198429B2 (en) | 2004-03-31 | 2007-04-03 | Fabcon, Inc. | Segmented concrete screed |
FI123542B (en) * | 2005-01-07 | 2013-06-28 | Elematic Oy Ab | Method, apparatus and forming part of a product for sliding molding of a concrete product |
RU107093U1 (en) * | 2010-11-30 | 2011-08-10 | Николай Станиславович Матвеев | EXTRUDER FOR MANUFACTURE OF CONCRETE PLATES |
FI124185B (en) | 2012-11-29 | 2014-04-15 | Elematic Oy Ab | Method and apparatus for casting concrete products |
-
2015
- 2015-01-27 FI FI20155054A patent/FI126200B/en not_active IP Right Cessation
- 2015-12-28 ES ES15202795.9T patent/ES2671029T3/en active Active
- 2015-12-28 EP EP15202795.9A patent/EP3056328B1/en not_active Not-in-force
- 2015-12-28 NO NO15202795A patent/NO3056328T3/no unknown
-
2016
- 2016-01-20 RU RU2016101509A patent/RU2645025C2/en active
- 2016-01-27 US US15/007,279 patent/US10434681B2/en not_active Expired - Fee Related
- 2016-01-27 CN CN201610058301.9A patent/CN105818251B/en not_active Expired - Fee Related
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20180133923A1 (en) * | 2016-11-14 | 2018-05-17 | Elematic Oyj | Method and apparatus for casting prefabricated concrete products |
US10759086B2 (en) * | 2016-11-14 | 2020-09-01 | Elematic Oyj | Method and apparatus for casting prefabricated concrete products |
CN107756600A (en) * | 2017-11-20 | 2018-03-06 | 上海师范大学 | Cement section of jurisdiction arc surface receives water floating device automatically |
US20200254647A1 (en) * | 2019-02-12 | 2020-08-13 | Elematic Oyj | Method for manufacturing prefabricated concrete products |
Also Published As
Publication number | Publication date |
---|---|
FI20155054A (en) | 2016-07-28 |
CN105818251A (en) | 2016-08-03 |
NO3056328T3 (en) | 2018-07-28 |
EP3056328A1 (en) | 2016-08-17 |
RU2016101509A (en) | 2017-07-26 |
ES2671029T3 (en) | 2018-06-04 |
US10434681B2 (en) | 2019-10-08 |
FI126200B (en) | 2016-08-15 |
EP3056328B1 (en) | 2018-02-28 |
RU2645025C2 (en) | 2018-02-15 |
CN105818251B (en) | 2018-09-07 |
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